Rug



Patented Sept. 7, 1948 UNITEDW STATES OFFICE direct and mesneassignments, to Libertyvilley Textileadne., Lbertyvilleflll., acorporation ofi Illinois Application September 23, 1945Seral No.(i1-9,133;

3V Claims. (Cl. filet-27 8)!1" This invention relates to "a rugv and' isDarticularly useful in the type ofrug in which pile warp threads arestitched 'toa fabric base.

The type of rug `in which .pile warp threads are stitched to a fabricbase is cheaply and easily formed because the pile threads can bestitched readily tothe'base inan inexpensive sewing opreati-on and'largevolumes of rugs are thus quickly produced.' Such rug-s, however, havethe sharp disadvantage ofp-resenting a rather'srnooth and flat surfacetothe oor andthe rugs slip easily when steppedA on. Furthermore, sincethepile warp threads themselves do not pass through the fabric basebutare secured to the base solely by threads, the structure is weak inthat tension placed upon anyof 'the warp threads tends to drawthe'stitching threads 'through'the fabricv andthus to lproduce anunevenpile. Since pile warp threads are --secured Vto the base by stitchingand .usually by sewing machine stitching, there is alimit to the sizeandcharacter of the stitching threads and the rug, which is otherwise4sturdy and serviceable, has. its 'weak 'link in vthe stitchingconnections.

An object ofthe presentLinvention's to provide the fabric base andstitched form' of rug referred .to with means for reinforcingthestitching threadsafter they are in place, to protect them againstbreaking and to lock them against being pulled through .the-fabric basewhile, at the saine "time, presenting to the floor surface means forretaining the rug-in placeoandfpreventing its slipping. A furtherobject'is to provide a rug formed of a fabric base and pile warp threadsstitched thereto in which at least some oi the stitching threadsextending to the underside of the fabric are provided with a `rugposition-fixing compositionv which strengthens the threads, locks `thernagainst being pulled |through the fabric, and provid-es a grippingsurface' which maintains the rugin position on 'the floor. Other objectsand advantages will appear as the specification proceeds.

The inventionlis illustrated'in a preferred embodiment, by theaccompanying drawing, in which- Figure l is la broken perspective viewof a portion of a rug constructed in accordance with my invention; Fig.2, a broken detailed view showing the stitching which connects the pilewarp thread-s to the fabric base; Fig. 3, a transverse sectional view ofa 'stitching thread provided with a coating of latex; Fig. 4, Va Viewsimilar to Fig. 3 but showing the stitching thread provided with aresinous coating; and Fig. 5, a view similar to Fig. 2..but showing the'threads overtwisted and" stitched tothe fabric iin over-twistedcondition.

In theillustrationgiven; I0 designates a fabric-base whichrnaycorrsistof canvas or any other suitable fabric .body'f' Tothe fabric base isstitched `the warp pile threads I I, which are-shown in the iormofloops'. The loops'may be over-twisted', as illustra'tediri Fig'. 5, oiwithouty twist, as illustrated in Figs. 1and'2; The warppilethreads maynot be in thefo'rrn` of loops 'but' may be stitched to 4the fabric 'inany other desired shape orlposition. Whenth'e threads II are s-titchedto the fabric inthe forrn illustrated, the loops themselves,` afterstitching," maybe severed at their tops 4or left intact.` t

The .stitchingof Ith'epil'e warp'threads II to the base Ilnay beaccomplished' in any desired'Y manner and by any i-ormiof'stitching. Ifdesired, a single-stitch thread may be employed to pass back andiortht'hrough' the fab-ric and about the threads yI I.` In the specificillustra-tion given, a bottom Ithr'eadflis 'employed onthel underside ofthe base Ianda stitching 'thread 'I3 is used to extend around thefbottomportions of the loops formed "by threads" 'Il `and to belocked on itsunderside by thethre'ads'IZ.' The bobbinor through-stitchingfthreads l 3Varel passed through the base Ill "at regularinte-rvals and theloopsformed 'underneath the'fzabri'c are engaged by the shuttle or`locling"thread"`l2"soas to secure the stitching threadl Biirmly `inposition;

In. the form'of v'stitching illustrated, Vas well as in other forms ofstitching, there is a'tendency vfor the` lower 'thread"l2to be drawnupwardly through the base when "great strain is suddenly placed 'uponone oiltheloops forming the warp pile above the base. 'Sometimes thestitching thread I2 breaks,'but often it issimply drawn-upwardlythrough'thebase. Further, the canvas bas'e'lfi,A whichis `corrstantly exposedtoa floor and oftento a waxed or'polished iifooigbecoines quite slipperyand the rug tends toslipeasily when steppedon'.y

I and that the above difn'cuides een be ova#- c-ome and a very sturdyand stable rug structure produced by providing one, or some, or anoccasional under-thread I2 in the rug with a coating or reinforcingcomposition which will strengthen the thread itself against being pulledthrough the rug and .against being broken, and which will furtherprovide a fri-ctional or weighted member for holding the rug in place.vThe thread I2 may be formed of cotton or any other suitable material andsprayed or drawn through a bath containing a composition adapted to thispurpose. For example, as shown in Fig. 3, the thread I2 may be drawnthrough a bath of latex so as to form a fabric core I4 covered by aresilient coating I5. The latex reinforces the cotton and -provides -atough sheath I5 resistant to the cutting influences of the upper threadI3. At the same time, the coating I5 is extremely -resistant to thefabric I9 and cannot be drawn through the fabric to release the upperthread I 3. Further, the latex coating provides a tenaceous surface,grips the floor, and maintains the rug frrrnly in position. Even thoughthere are just a few of the threads I2 appearing on lthe underside ofthe rug, the combined effect of such threads serves to stabilize the rugin its position on the floor.

The treated thread I2 serves a further function in areas like porches,where the wind tends to carry the light rug from its position on thefloor. Here the additional weight of the treated thr-eads tends to x theposition of the rug.

In Fig. 4 is illustrated a thread having a fibrous core I6 and which isreinforced with a resinous material Il. The resinous material may be ofany suitable composition which will reinforce the thread againstbreaking and against being drawn through the rug and which will, at thesame time,

tend to maintain the rug in its position on the floor. For example,resin such as methacrylate, vinyl resins, alkyd and any natural resin,as Well as resin-like materials consisting of cellulose esters orderivatives, and cellulose acetate and cellu lose acetate-butyrate. Suchresins not only strengthen the thread but also have thermoplasticcharacteristics which enable them to be firmly united in the rug andwhen the rug is formed will, upon setting, tend to lock the stitchingthreads I3 rmly in place. It Will be understood that there are a varietyof resins and resin-like materials which Will permeate the thread Ill orform a coating on the fibrous center thereof while still providing aflexible thread which may be fed through the machine for locking thelower loops of stitching thread I3.

A very attractive and satisfactory rug is formed when the loops of thewarp thread II are given an over-twist and then stitched in positionupon the fabric III as indicated in Fig. 5, the overu twisted loop beingindicated by the numeral I8.

In the operation of the structure, the canvas base I0 which supports thelooped pile thread II serves as a secure anchor for the loops by reasonof the locking thread I2 which engages the loop lportion of the stitchedthread I3 when it comes through the fabric. The coated thread I2 withits latex or resin coating is resistant to tearing and further resistsany tension placed upon the thread I3 which might otherwise tend to drawit through the fabric. The latex coating permits a slight yielding underthe tension but restores the threads I2 and I3 to their originalposition after the tensile strain ceases.

It will be understood that instead of employing la locking thread I2extending all the Way under the fabric, a stitching thread may beemployed which will extend through the fabric repeatedly and will serveto lock the pile threads I I to the fabric. Such a stitching thread ispreferably formed and treated like thread I2 in the illustration givenand serves the same purpose of locking the members II in position,preventing tearing of the threads and also providing means on the bottomside for maintaining the rug in position. While stitching thread I 3 hasbeen described herein as a non-treated thread and thread I2 has beendescribed as the treated thread, it will be understood that such anarrangement may be reversed and that the thread I3, which extendsthrough the fabric, may be treated and thread I2 may be left untreatedor, if desired, both threads E2 and I3 may be treated as describedherein.

While in the foregoing description, I have set forth many details asillustrating one mode for use of the invention, it will be understoodthat such details may be Widely varied by those skilled in the artwithout departing from the spirit of my invention and the claims hereinshould be looked to as definitive of the scope of the invention.

I claim:

1. A rug, comprising a finished fabric base, pile Warp threads formingloops, and stitching threads `extending through the base and around thelower portions of the loops to secure them to the base, said stitchingthreads being covered with a resilient material which yields upon thepulling of the loops.

2. A rug, comprising a finished fabric base, pile warp threads alignedthereon in loop formation, and chain-stitching threads securing saidloops to said base, the lowermost of said chain-stitching threadsextending through said fabric and being coated with a resilient body.

3. A rug, comprising a canvas base, pile Warp threads aligned thereon inloop formation, and chain-stitching threads securing said loops to saidbase, at least the lowermost of said chain-stitching threads lying onthe underside of said fabric and being coated with rubber, said coatingproducing a yielding of the stitching threads when tensile strain isapplied to one of said loops.

WILLIAM F. STAHL.

REFERENCES CITED The following references are of record in the iile ofthis patent:

UNITED STATES PATENTS Great Britain Mar. 13, 1918

